EXTERNAL INTEGRATED SUMMATIVE ASSESSMENT EXEMPLAR …

Page 1 of 26 Exemplar 1C OC: Maintenance Planner (101874)

EXTERNAL INTEGRATED SUMMATIVE ASSESSMENT

EXEMPLAR 1C

GENERAL EISA RULES

1. Students are only allowed to use the supplied EISA booklets. 2. Students are only allowed to use a black pen for their answers. 3. Students to ensure that their name, surname and EISA registration number appears on

the front of your EISA booklet. 4. This is a closed book examination; therefore, no other material or belongings are to be

brought into the assessment centre. Should you bring any other material or belongings into the assessment centre, you will be required to leave such at the front of the assessment centre examination room. The assessment centre will not be held liable for any loss or damage to property brought into the assessment centre examination room.

5. All EISA booklets must be handed back to the invigilator intact. No pages may be torn off from the EISA booklet. The removal of EISA booklets from the examination room is prohibited.

6. Students may make use of a calculator in this EISA. 7. Unless this is an online examination where access to a computer will be made available

to you; the use of any communication devices, including smart watches, cell phones, tablets, i-Pads, headphones and laptops are prohibited.

8. All cell phones are to be switched off for the duration of the EISA. 9. The invigilator will not assist you with the explanation of questions related to the EISA. 10. Students are prohibited from conversing in any manner with other students. 11. Students may not leave the examination venue within one hour of the start of the

examination and in the last 10 minutes of the allotted examination period. 12. Students who are found to be disruptive and unruly in the assessment centre will be

requested to leave the assessment centre by the invigilator. I HEREBY CONFIRM THAT I HAVE READ THE ABOVE EISA RULES AND DECLARE THAT I

UNDERSTAND AND ACCEPT THE RULES.

SIGNATURE OF STUDENT

STUDENT NAME & SURNAME

ID NUMBER

EISA REGISTRATION NUMBER

ASSESSMENT CENTRE

ASSESSMENT CENTRE ACCREDITATION NUMBER

QUALIFICATION Occupational Certificate: Maintenance Planner

SAQA ID 101874

CREDITS 261

PAPER 1C (there are 3 papers to be written: 1A; 1B and 1C)

DATE OF EISA

DURATION 3 Hours

TOTAL MARKS 160


CANDIDATE INSTRUCTIONS

• Candidates must complete all questions in this EISA.

• Candidates must ensure that they use only a black pen when completing this EISA.

• Should you require additional space to complete your answer, please request additional

paper from your invigilator. Ensure that you indicate your name, surname and EISA

registration number at the top of the additional paper. Also ensure that the question

number is clearly marked on your additional paper


ELO 2: Coordinate the implementation and execution of the schedule

Question 1.1 Coordinate the execution of tasks (45 marks)

INFORMATION PACK

Extract from Master Plan

Item Functional location

Task Description Work center

Duration Planned date

1 Mixing Replace Motor ZM- Elect 4hrs 3 May 2021

User Department: Finishing Job plan information

Task description: Replace Motor (75 kW) Department: Mixing Department Location: Line 1 Skilled required: 1 x Fitter 1 x Electrician 1 x Rigger 1 x Laser and vibration Technician (External services) Hours required: 4 hours Parts: Part# 11111 Motor, Electric Special tools: Torque wrench Laser alignment Vibration analysis Slings Special equipment: Jib Crane / Forklift Steps: Step 1: Lock out / tag out Step 2: Disconnect motor, mark/label wires Step 3: Unbolt coupling, inspect coupling and remove motor bolts Step 4: Remove motor using jib crane available Step 5: Install new motor (check motor is rotating freely) Step 6: Connect coupling Step 7: Alignment Step 8: Connect the motor and check for right rotation Step 9: Vibration analysis Step 8: Test run Step 9: Clean up and return motor to service Step 10: Close out the work order detailing what was done


Question 1.1.1 (10 marks)

Refer to Information Pack above and answer the following:

The work pack consists of several items that are essential for effective and efficient execution of

maintenance task in the schedule.

1.1.1.1 List and explain any five (5) items which form part of the work pack.

(5 marks)

1.1.1.2 Outline the process you will follow to coordinate and confirm the items in the work pack

prior to execution.

(5 marks)



1.1.2.1 The work pack has been confirmed, issued and is at execution stage. As a maintenance

planner illustrate the process you will follow to further ensure that all resources in work

pack are readily available on the planned date of task execution.

(10 marks)


1.1.2.2 Identify any five (5) delays that may occur during the execution of this maintenance task.

(5 marks)


1.1.3.1 The maintenance planner needs to have various skills to coordinate and provide

support to the maintenance and operations/production departments during

maintenance task execution.

List and explain various skills the maintenance planner should have in order to fulfill

this role efficiently and effectively. Illustrate your answer with practical example within

maintenance planning

(10 marks)


1.1.3.2 Refer to the scenario below and Information Pack above and answer the question.

Scenario

During task execution the Fitter discovered that the coupling is worn and it needs replacement. A

separate notification/work request was raised as matter urgency. The planner was notified of the

emergent work and was requested to expedite the spare part. Due to this, the task will be delayed

in order to install new coupling. Consequence to this the production start time will be delayed.

How will you ensure effective communications to affected role players due to this delay?

(10 marks)



ELO 3: Close all work requests successfully and review the outcomes

List of tables to refer to for next section – Questions 2.1 and 2.2 where applicable as instructed

Status Description

COM Complete, job done

WIP Work in progress

OUT Outstanding

CAN Cancelled, no longer required

RES Rescheduled

Table 1: Illustrates various types of work order statuses

Work Order Type

Description

PM01 Corrective Maintenance (Planned, Unplanned)

PM02 Preventive Maintenance

PM03 Predictive Maintenance

PM04 Statutory Maintenance (Legal)

PM05 Change Management

Table 2: Illustrates various types of work orders

Work Centre Description

ZFEL Electrical Foreman

ZFEM Mechanical Foreman

ZFIN Instrument Foreman

ZFEMX External Services (SLA)

Table 3: Illustrates various types of work centers

Key Performance Indicator Target

Work order turnover 100%

Schedule compliance 80%

Planning Degree 80%

Schedule adherence 80%

Statutory compliance 100%

Table 4: Illustrates KPI targets


Schedule Week: Week 09,

Schedule Date: 03 March 2021 – 05 March 2021

Table 5: Summary report which illustrates a schedule for week 09.

FUNCTIONAL LOCATION

MAIN WORK

CENTER

WORK ORDER

DUR. (H) TASK DESCRIPTION ORDER TYPE

SCHED. START DATE

START TIME

RESOURCE FEEDBACK STATUS

Line 1 ZFEL1 2021001 2,0 Change fan motor PM01 03 March 2021 09:00 Artisan A

Job done. Create a 1Monthly maintenance plan to lubricate fan bearings for 1 hour. See approval docs)

COM

Line 1 ZFEL1 2021002 2,0 1W MIXER ELEC INSPECTION

PM03 03 March 2021 09:00 Artisan A Mixer is obsolete, please delete schedule (see approval docs).

COM

Line 1 ZFEL1 2021003 2,0 Replace cooling fan PM01 03 March 2021 09:00 Artisan A Job not done, spare item was supplied with a wrong shaft size. Lifting equipment also not available

WIP

Line 1 ZFEL1 2021004 2,0 1M GEARBOX MOTOR INSPECTION

PM03 03 March 2021 09:00 Artisan A Job not done, reschedule Artisan not available

OUT

Line 1 ZFIN1 2021005 2,0 1W TANK LOAD CELL CALIBRATION

PM02 04 March 2021 09:00 Artisan B

Job not done, reschedule Production did not handover Equipment not available to do the task

CAN

Line 1 ZFIN1 2021006 2,0 1W SCALE CALIBRATION

PM02 04 March 2021 09:00 Artisan B Job done. Final report submitted. Certificates to be submitted.

OUT

Line 1 ZFMEX 2021007 2,0 1M GEARBOX VIBRATION ANALYSIS

PM03 04 March 2021 09:00 Artisan C,

Contractors

Findings Increase in the overall vibration levels in the motor and plummer bearing spectrums Recommendations Inspect the security of the plummer bearing spectrums.

COM

Line 1 ZFME1 2021008 2,0 3YEARLY PRESSURE TEST ON AIR RECEIVER

PM04 03 March 2021 09:00 Artisan C Job done, no fault found. Final report submitted. Certificates to be submitted.

COM

Line 1 ZFMEX 2021009 3,0 Change gearbox PM01 03 March 2021 09:00 Artisan C,

Contractors

Job done but was handed over late to operations by 4 hours. SLA not complied with.

COM

Line 1 ZFME1 2021010 3,0 Change bearings PM01 03 March 2021 09:00 Artisan C Job done, no fault found COM

Line 1 ZFME1 2021011 3,0 3YEARLY PRESSURE TEST ON PRESSURE RELIEF VALVE

PM04 05 March 2021 09:00 Artisan C Job done, no fault found. Final report submitted.

COM

Line 1 ZFME1 2021012 2,0 3YR PASSENGER LIFT LOAD TEST

PM04 05 March 2021 09:00 Artisan C Job done, no fault found. Final report submitted.

COM


ELO 3: Close all work requests successfully and review the outcomes

Question 2.1 Close out documentation 80 marks

Insert table report


A work order/job card was issued to carry out statutory test (legal) on a hazardous piece of

equipment as required by Occupational Health and Safety Act (OHS Act)

Outline the list of items that you will evaluate in this work order and related documentation in order

to ensure that the feedback provided is completed accurately and correctly. Illustrate your answer

with any statutory equipment that you are familiar with.

(15 Marks)


Question 2.1.2 (15 Marks)

As maintenance planner your function is to review completed tasks, capture work history in CMMS

and provide necessary feedback to various role players and departments.

In your role as maintenance planner outline how you will do the following:

2.1.2.1 The process to review completed tasks. (5 marks)


2.1.2.2 The process of capturing history in CMMS. (5 marks)

2.1.2.3 The process of providing feedback where necessary. (5 marks)



Maintenance reports provides an opportunity to review the performance of the maintenance

department. Maintenance planning plays an important roles in reporting on various Key

Performance Indicators (KPIs).

2.1.3.1 What is your understanding of the following Key Performance Indicators (KPIs) in planning? Select and answer any five (5) KPIs below.

or

Alternatively you may list and explain any five (5) Key Performance Indicators (KPIs) in planning that you are familiar with.

(10 marks)

a) Work order turnover (2 marks)

b) Backlog

(2marks)

c) Schedule compliance (2 marks)


d) Statutory compliance (2 marks)

e) Labour utilization (2 marks)

f) Planning Degree (2 marks)

g) Scheduling Efficiency (2 marks)


h) Schedule adherence

2.1.3.1 Refer to Table 5: Summary report above

Calculate any of the following five (5) KPIs. You are required to indicate the formula used.

or

Alternatively you may calculate any five (5) key performance indicators that you are familiar with. You are required to indicate the formula used.

(10 marks) a) Work order turnover

(2marks)

b) Backlog

(2 marks)


c) Schedule compliance

(2 marks)

d) Statutory compliance

(2 marks)

e) Labour utilization

(2 marks)

f) Planning Degree

(2 marks)


g) Scheduling Efficiency

(2 marks)

i) Schedule adherence


Service Level Agreement Scenario:

The service provider is contracted to service Switch Gear for Line 2. The service level agreements

standards are outlined in the table below.

KPIs and Metrics

Metric Commitment Measurement

Availability 100% MTTR

Reliability 100% MTTF

Service Levels, Rankings, and Priority

Severity Level Description Target Response

1. Outage Switch gear down Immediate 30 minutes

2. Critical High risk of Switch gear downtime Within 1 hour minutes

3. Urgent End-user impact initiated Within 20 minutes

4. Important Potential for performance impact if not addressed Within 2 hours


According to your record the monthly summary report is as follows:

• Availability is 96%

• Reliability is 98%

• Response time for severity 2 critical was 2 hours

Contractor’s Report: the service provider has submitted a report stating that all the service levels

have been complied with satisfactorily.

Answer the following:

2.1.4.1 What is your understanding of the Service Level Agreement (SLA) and what is its

importance to in maintenance planning function? List any five (5) explanations

associated with Service Level Agreement.

(5 marks)

2.1.4.2 According to your understanding of the SLA how would you verify the submitted

report as a maintenance planner and how would you enforce deviations of non-

conformances?

(10 marks)


Question 2.1.5

Illustrate the process of closing out a work order and maintaining relevant documents by listing required input on the CMMIS. (5 marks)

Question 2.1.6

Based on the above summary report on Table 5, identify any five (5) work orders with outstanding issues and explain how you would manage them.

(10 marks)



Question 2.2 Review the execution outcomes of the work management process 35 marks


You are required to identify scheduling constrains and improvement opportunities.

Refer to Table 5(summary report week 9)

a) Identify any five (5) scheduling constrains (5 marks)

b) List any five (5) improvement any opportunities (5

marks)



Based on the summary report on table 5, identify any two (2) work orders that require system or

master data updates. List steps or process you will follow when updating master data.

Master Update 1 (5 marks)

Master Update 2 (5 marks)


Question 2.2.3

You are required to outline a process on how to you go about to identify, formulate and implement

areas that require improvements in planning.

To answer this question analyse summary report week 9 on table 5. Further compare the actual

KPIs you calculated in question 2.1.3.2 against the Target KPI on Table 4.

(10 marks)


(TOTAL MARKS FOR THE EXAM: 160)

MARK ALLOCATION GRID (For use by the Assessor only)

QUESTION MARK MARKS AWARDED

1.1.1 10

1.1.2 15

1.1.3 20

TOTAL QUESTION 1.1 45

2.1.1 15

2.1.2 15

2.1.3 20

2.1.4 15

2.1.5 5

2.1.6 10


2.2.1 10

2.2.2 10

2.2.3 15


GRAND TOTAL 160


ASSESORS DETAILS

ASSESSOR NAME & SURNAME

REGISTRATION NUMBER

SIGNATURE

DATE

INTERNAL MODERATOR DETAIL

MODERATOR NAME & SURNAME

REGISTRATION NUMBER

SIGNATURE

DATE

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EXTERNAL INTEGRATED SUMMATIVE ASSESSMENT EXEMPLAR …